Well a few weeks ago snagged a aluminum rear bumper from a 760 turbo Volvo. I wanted to do this now because I have an evo suspension set on the way and want to get the ride high set once and for all.
This so far has been one of the easiest fabrication exercises yet.
I removed all the 10mm bolts that hold the side to the body then the 14mm's in the aft of the trunk. She fell right out. First thing I did was weigh it my 50 pound spring scale instantly maxed out so I went to the bath room for the house scale.
I removeded about 30 10mm's bolts and pulled the heavy bitch off the cover. About 30 % of them broke off from rust.
Now for the mounts. I spoted all the spot welds with a center punch the started drilling 3/8 holes (11 on each mount) They fell right off then reinstalled them on the car for fitment for fitment. They are perfect the volvo bumper slides right into them.
I've started cutting the ends of the bumper off. This is some super hardened aluminum. My diamond wheel usually eats through aluminum but this stuff is just dusting off. I may run into town and use a band saw at my buddies shop.
As for the mounts for the bumper cover. Im going to take some light weight sheetmetal and bend and rivet it to the bumper and zip tie or use some off the plastic insert screw thingys that mitsubishi loves to put on cover plates.
When I'm done this thing should weigh about 20 pounds total including the cover. And not be rusted out. Both ends were eat up from rust and I have a pile of rust scale in the drive way the size of a basketball.
More photos as progress comes along.